CN110027454B

CN110027454B - Condensation and humidity sensor for thermoelectric devices

Info

Publication number: CN110027454B
Application number: CN201811430679.2A
Authority: CN
Inventors: 约翰·洛菲
Original assignee: Gentherm Inc
Current assignee: Gentherm Inc
Priority date: 2008-02-01
Filing date: 2009-01-30
Publication date: 2022-04-08
Anticipated expiration: 2029-01-30
Also published as: US9651279B2; CN110027454A; KR20160049057A; EP3121061B1; EP3121061A1; US20090193814A1; EP2234839A1; EP3121060A1; CN105291920A; JP2011514180A; WO2009097572A1; US8505320B2; KR101779870B1; US10228166B2; US20140130516A1; US20150013346A1; US8256236B2; EP2234839B1; CN105291920B; EP2234839A4

Abstract

According to some embodiments disclosed in the present application, a climate controlled seat assembly includes a thermal module. The thermal module includes at least one inlet channel, at least one outlet channel, and a thermoelectric device (e.g., peltier circuit) located upstream of the outlet channel. In one embodiment, the seat assembly includes a sensor positioned inside the thermal module and configured to detect the presence of a liquid, such as water, condensate, or other fluid, on or near the sensor. In some configurations, the sensor is configured to detect the presence of a liquid by measuring a resistance or capacitance across a portion of the sensor. The climate control system may include an insulation pad positioned within the housing of the fluid module and at least partially between the cold aisle and the hot aisle. In some embodiments, the release liner includes one or more wicking materials. The insulation blanket may be configured to transfer liquid from the cold aisle to the hot aisle.

Description

Condensation and humidity sensor for thermoelectric devices

The present application is a divisional application of a patent application entitled "condensation and humidity sensor for thermoelectric device" by josephson corporation, having application number 201510673550.4, filed on divisional date of 2009, 1, and 30, 2015, 10, and 16, and filed on singular opinion of first review notice No. 2017042801748840, published on 04, 2017, 05, and month.

Cross Reference to Related Applications

The present application claims the benefit of priority from U.S. provisional application No.61/025,694 filed 2/1/2008 and U.S. provisional application No.61/025,719 filed 2/1/2008, to 119(e), the entire contents of which are incorporated herein by reference.

Technical Field

The present application relates generally to climate control and, more particularly, to climate control of a seat assembly employing thermoelectric circuits.

Background

Typically, temperature conditioned air for a residential or workspace environment may be provided to a relatively wide area, such as an entire building, a selected office, or suite within a building. For vehicles, such as automobiles, typically the entire vehicle may be heated or cooled as a unit. However, it is desirable to have more selective or restrictive air temperature conditioning. For example, it is often desirable to provide individual climate control for the passenger's seat so that substantially instantaneous heating or cooling can be achieved. For example, a vehicle exposed to summer weather, particularly when the vehicle has been parked in an unshaded area for an extended period of time, can result in a vehicle seat that is hot and sometimes uncomfortable for passengers to enter the vehicle even with ordinary air conditioning. Further, even with ordinary air conditioning, on a hot day, the back or other pressure points of the passenger may still sweat when seated. In winter, it is highly desirable to heat the passenger's seat quickly in order to make the passenger feel comfortable. This is particularly true when the conventional vehicle heater is not capable of rapidly heating the vehicle interior. For these and other reasons, various types of individual vehicle seat climate control systems have emerged. Recently, individual climate control systems have been expanded to beds, chairs, wheelchairs, and the like.

Such climate control systems typically include a distribution system that includes a combination of conduits and channels formed in one or more cushions of the seat. By using climate controlled devices, air to be climate conditioned can be supplied to these ducts and channels. Air that is climate conditioned flows through the ducts and channels to cool or heat the space adjacent the vehicle seat surface.

However, different problems have arisen with existing climate control systems. For example, some control systems utilize thermoelectric devices (TEDs) that can have a variety of configurations on both the hot and primary sides of the device. For a construction in which there is a heat exchanger on the primary side through which air flows, the condensate may be formed by water in the air. Whether or not condensation will occur, and how much condensation will occur, depends on the ambient air conditions (i.e., temperature and relative humidity) and the amount of temperature reduction from the inlet to the outlet of the primary side heat exchanger. Such condensation can have undesirable consequences ranging from corrosion of metal parts to the generation of mold. The condensate may also partially or completely block airflow at the fan passage on the primary side of the TED, resulting in reduced or lost functionality.

Disclosure of Invention

According to some embodiments disclosed in the present application, a climate controlled seat assembly includes a thermal module. The thermal module includes at least one inlet channel, at least one outlet channel, and a thermoelectric device (and, peltier circuit) located upstream of the outlet channel. According to some configurations, the thermoelectric device is configured to selectively heat or cool a fluid passing through an interior of the thermal module. The climate controlled seat assembly also includes a fluid transport device, such as a fan or blower, configured to transport fluid from the inlet channel to the outlet channel of the thermal module through the thermoelectric device. In one embodiment, the seat assembly further comprises a sensor positioned inside the thermal module and configured to detect the presence of a liquid, such as water, condensate, or other fluid, on or near the sensor. In some configurations, the sensor is configured to detect the presence of a liquid by measuring a resistance or capacitance across a portion of the sensor. Alternatively, the sensor detects the presence of the liquid using any other method.

According to some embodiments, the sensor includes at least a second and a second conductive member (e.g., an electrical trace). In one embodiment, the sensor is configured to measure resistance or capacitance on a trace or other conductive member. In another configuration, the sensor is positioned on the thermoelectric device, or along the cooling side of the thermoelectric device. In some embodiments, the sensor is positioned along an outlet channel adapted to receive a fluid (e.g., air) cooled by the thermoelectric device.

In other constructions, the first and/or second electrically conductive members are etched on a substrate of the thermoelectric device. In another configuration, the substrate comprises polyimide, epoxy, ceramic, or other suitable material. In other embodiments, the voltage supplied to the thermoelectric device is configured to decrease if the presence of liquid is detected by the sensor. According to other configurations, the seat assembly includes an automobile or other type of vehicle seat, a bed, a wheelchair, a sofa, an office chair, a hospital bed, and the like.

According to some embodiments of the present application, a method of controlling a thermoelectric device configured for use in a climate controlled seat assembly includes providing a fluid module adapted to provide heated or cooled air to the climate controlled seat assembly. In some arrangements, the fluidic module includes a thermoelectric device configured to selectively heat or cool a fluid passing through the interior of the thermal module and a fluid transport device (e.g., a fan, blower, etc.) configured to pass air through the interior of the fluidic module via the thermoelectric device. The method also includes positioning a sensor within the fluid module, wherein the sensor is configured to detect condensate and/or other liquids it contacts. Also, the method includes detecting a first voltage to the thermoelectric device to selectively heat or cool air conveyed through the fluid module. In some embodiments, wherein a second voltage less than the first voltage is applied to the thermoelectric device when the sensor detects condensate and/or other liquid.

In some configurations, the sensor is configured to detect condensation and/or other liquids by measuring a resistance or capacitance across a portion of the sensor. In some embodiments, the sensor positively detects condensate and/or other liquids when the resistance or capacitance thereon changes by at least 2%, 5%, 10%, 20%, or more than 20% over a time period of 1 minute, 2 minutes, 5 minutes, 10 minutes, or 15 minutes (or a time period of less than 1 minute, a time period of more than 15 minutes, and/or any other time period). In some embodiments, the second voltage is zero, so as not to supply current to the thermoelectric device. Thus, the thermoelectric device may be deactivated when the sensor detects condensate and/or other liquid. In another configuration, the sensor is positioned on the thermoelectric device, or along the cooling side of the thermoelectric device. In other embodiments the sensor is positioned along an outlet of the fluidic module, the outlet being positioned substantially downstream of the thermoelectric device. The outlet is configured to receive air that has been cooled by the thermoelectric device.

According to another embodiment, a fluid regulating device for use with a climate controlled seat assembly comprises: the thermoelectric device includes a fluid module including a housing, a fluid delivery device configured to deliver a fluid through an interior of the housing, and a thermoelectric device configured to selectively heat or cool the fluid passing through the interior of the housing. The thermoelectric device may include a hot side in fluid communication with the hot channel and a cold side in fluid communication with the cold channel. In some configurations, the hot channel is configured to receive air heated by the thermoelectric device, wherein the cold channel is configured to receive air cooled by the thermoelectric device. The hot and cold channels are located downstream of the thermoelectric device and within the housing of the fluid module. The fluid regulating device also includes a separator pad positioned within the housing and at least partially between the cold and hot channels, the separator pad including one or more wicking materials. The insulation blanket may be configured to transport liquid from the cold aisle to the hot aisle.

In some embodiments, the release liner comprises a porous structure. In other constructions, the wicking material includes polypropylene, nylon, and/or any other material or construction. In other constructions, the liquid delivered to the thermal channel is configured to be vaporized. In another embodiment, the fluid regulating device further comprises at least one wicking material finger extending at least partially through the housing of the thermoelectric device. The wicking material fingers may be configured to transport liquid from the thermoelectric device to the release liner.

According to some embodiments of the present application, a method of automatically adjusting a climate controlled seat assembly using an automatic control mode includes providing a fluid module in fluid communication with at least one fluid distribution channel of the seat assembly. In some embodiments, the fluid module includes a thermoelectric device configured to selectively heat or cool a fluid passing through the fluid module, and a fluid transport device configured to transport the fluid through the fluid module. The fluid delivery device includes an inlet and an outlet. The method of automatically adjusting a seat assembly also includes sensing a temperature of a fluid present at an outlet of the fluid delivery device, sensing a relative humidity of the fluid present at the outlet of the fluid delivery device, and providing the temperature and the relative humidity as inputs into the control mode protocol. Moreover, the method includes modifying an operating parameter of the thermoelectric device and/or the fluid delivery device based on instructions provided by the control mode protocol.

In some embodiments, the seat assembly includes an automobile seat, other vehicle seat, a bed, a wheelchair, an office chair, a sofa, a hospital bed, and the like. In some embodiments, the method further comprises detecting the temperature of the ambient air. The control mode protocol is configured to also receive as input the temperature of the ambient air. In other constructions, the method further includes detecting the presence of an occupant positioned on the seat assembly using an occupant detection sensor. In one embodiment, the step of modifying the operating parameter includes the step of adjusting the voltage or current supplied to the thermoelectric device, the step of adjusting the speed of the fluid delivery device, or the like.

In some configurations, the thermoelectric device may include a peltier circuit and a sensor that determines the presence of fluid at the sensor by measuring a change in resistance or capacitance. When the sensor measures such a change in resistance or capacitance, the voltage to the thermoelectric device may be reduced or eliminated altogether. The fluid may be water or condensate formed within the climate controlled system.

In some embodiments, the thermoelectric device includes a protruding portion (ridge) that protrudes through the peltier circuit, wherein a portion of the entire sensor is located on the protruding portion. The protruding portion may include a substrate. The substrate may be formed of copper.

In some embodiments, the sensor is on a primary side of the thermoelectric device.

The thermoelectric device may include a peltier circuit, at least one heat sink, and a sensor that determines the presence of water at the sensor by measuring a change in resistance or capacitance. The sensor may be located downstream of the at least one heat sink.

A sensor for detecting the presence of fluid at the sensor may include one or more conductive traces. Where the sensor includes two or more conductive traces, the traces may be maintained in substantially the same spacing apart from each other. The sensor may measure a change in resistance between the two traces. The resistance change may be an insulation value or a rapid change over a short period of time. Where the sensor comprises a trace, the sensor may further comprise a conductive surface. The electrically conductive surface may comprise a heat transfer member, such as at least one heat sink. The sensor may measure a change in resistance between the trace and the heat transfer member.

In some embodiments, the traces are etched on the substrate. The substrate may comprise polyimide.

A sensor for detecting the presence of fluid at the sensor may also measure capacitance rather than resistance. The sensor may include first and second conductive plates, and a material that absorbs water intermediate the first and second conductive plates. In some embodiments, the intermediate material comprises polyimide and the first and second conductive plates may comprise copper.

In some embodiments, the first conductive plate may include an electrical connection tab that is part of the TED. The second conductive plate may include a thermally conductive element that is also part of the TED. The material in the middle may include a substrate that is also part of the TED.

In some embodiments of the sensor employing capacitance to detect the presence of a fluid, the second conductive plate includes at least one aperture etched in a surface of the plate for increasing the surface area of the material therebetween exposed to absorb the fluid. The holes may be disposed substantially throughout the substrate, or they may be located at locations where condensate formation is likely to be high.

The climate controlled vehicle seat may include a fluid distribution system and a fluid module including a fluid delivery device, a thermoelectric device, and a sensor that detects the presence of water at the sensor by measuring a change in resistance or capacitance. The climate controlled vehicle seat may also include a voltage to the thermoelectric device that is reduced when the sensor detects a change in resistance or capacitance.

The climate controlled bed may include a fluid distribution system and a fluid module including a fluid transport device, a thermoelectric device, and a sensor that detects the presence of water at the sensor by measuring a change in resistance or capacitance. The climate controlled bed may also include a voltage reduction to the thermoelectric device when the sensor detects a change in resistance or capacitance.

One configuration of the TED assembly has heat sinks on both sides of the TED and air blown across both sides. Downstream of the heat sink, it is often desirable to have the hot and cold air streams separate from each other so that the regulated control can be used for functional purposes. One way to do this is to place a block of foam material between a hot sink and a cold sink that will physically separate the air flow and also act as a thermal barrier between them (e.g., to prevent the hot air from heating the cooled air).

One embodiment of the present invention replaces such (typically foam) release liners with wicking release liners. If condensation does not occur on the cold side air stream, the water formed will cross the release liner by capillary action to the other side (through which the hot air flows) and be evaporated and carried away by the hot air. In this way, the condensate formed is removed from the cold side of the TED.

For the case where water condenses on the cold side of the TED assembly, the wicking barrier liner will remove the condensed liquid.

This allows the TED components to be designed with high thermal performance that could otherwise be achieved. In other words, the TED may be designed to provide high temperature variations on the cold side air flow. Alternatively, the TED may operate in a high humidity ambient environment.

In another embodiment, finger wicking may extend between the cold side heat sink of the TED and the hot side of the air flow. Finger wicking can draw moisture away from the fins and transport it to the hot side of the air stream; this moisture can then evaporate into the hot air.

Drawings

These and other features, aspects, and advantages of the present invention are described herein in connection with certain preferred embodiments with reference to the accompanying drawings. However, the illustrated embodiments are exemplary only, and are not intended to limit the present invention. The drawings include the following figures.

FIG. 1 illustrates a side view of a climate controlled vehicle seat according to one embodiment;

FIG. 2 illustrates a perspective view of a climate controlled bed according to one embodiment;

FIG. 3 illustrates a partial cross-sectional view of a fluidic module according to one embodiment;

FIG. 4A illustrates a partial cross-sectional view of a fluidic module including a wicking barrier liner according to one embodiment;

FIG. 4B illustrates a partial cross-sectional view of the fluid module of FIG. 4A when condensate is present;

FIG. 5 illustrates a partial cross-sectional view of a fluidic module including a finger-like wicking and wicking barrier liner according to one embodiment;

FIG. 6A illustrates a top schematic view of a resistance-based condensate sensor;

fig. 6B illustrates a top schematic view of a sensing region of the coagulation sensor of fig. 6A;

FIG. 6C illustrates a top schematic view of another embodiment of a resistance-based condensate sensor;

FIG. 6D illustrates a top schematic view of yet another embodiment of a resistance-based coagulum sensor;

FIG. 6E illustrates a top schematic view of yet another embodiment of a resistance-based coagulum sensor;

FIG. 7 illustrates a perspective view of another embodiment of a resistance-based condensate sensor;

FIG. 8 illustrates a graph of resistance measured at a resistance-based coagulum sensor over time, according to one embodiment;

FIG. 9A illustrates an exploded perspective view of a thermoelectric device according to one embodiment;

FIG. 9B illustrates an assembled perspective view of the thermoelectric device of FIG. 9A;

FIG. 10A illustrates a partial cross-sectional view of a fluid module including a condensate sensor according to one embodiment;

FIG. 10B illustrates a perspective view of an assembled form of a thermoelectric device including a condensate sensor according to one embodiment;

FIG. 10C illustrates a perspective view of an assembled form of a thermoelectric device including a condensate sensor according to another embodiment;

FIG. 11A illustrates a schematic perspective view showing the general principles of a capacitance-based coagulation sensor according to one embodiment;

FIG. 11B illustrates an exploded perspective view of a condensate sensor using capacitance to measure the presence of fluid according to one embodiment;

FIG. 12 illustrates an embodiment of a circuit including a condensate sensor;

FIG. 13 illustrates one embodiment of a comfort zone related to temperature and relative humidity;

FIG. 14A illustrates an embodiment of a climate controlled seat assembly including a plurality of sensors according to an embodiment; and

FIG. 14B illustrates an embodiment of a climate controlled bed including a plurality of sensors according to an embodiment.

Detailed Description

The various embodiments described below illustrate various structures that may be used to achieve the desired improvements. These particular embodiments and examples are illustrative only and are not intended to limit the general inventions presented herein and the various aspects and features of these inventions. Further, it should be understood that the terms cooling side, heating side, primary side, discharge side, cooler side, hotter side, etc. do not denote any particular temperature, but rather are relative terms. For example, the "hot," "heating," or "hotter" side of a thermoelectric device or array may be ambient temperature, with the "cold," "cooling," or "colder" side being at a cooler temperature than ambient temperature. Conversely, the "cold", "cooling" or "colder" side may be at ambient temperature, while the "hot", "heating" or "hotter" side is at a higher temperature than ambient temperature. Thus, these terms are relative to each other and are used to indicate that one side of the thermoelectric device is at a higher or lower temperature than the opposite or opposite side. Also, as is well known in the art, when the current in a thermoelectric device is reversed, heat can be transferred to the "cold" side of the device while heat is being drawn from the "hot" side of the device. Further, in the following discussion fluid flow is referenced as having a direction. When such references are made, they generally refer to directions as depicted in the two-dimensional figures. The term indicating "away" or "along" or any other fluid flow direction described in this application, when considered in terms of a perspective view of a two-dimensional map, means an illustrative generalization of the flow direction.

Fig. 1 is a schematic view of a climate controlled vehicle seat 10. The illustrated climate controlled vehicle seat 10 includes a seat back 2, a seat bottom 4, a fluid distribution system 12, and a fluid module 14. The terms "fluidic module" and "thermal module" are used interchangeably herein. The fluid module 14 may include a fluid delivery device 16 and a thermoelectric device (TED) 18. The fluid delivery device 16 comprises, for example, a blower or a fan. FIG. 1 illustrates one embodiment of a climate controlled vehicle seat 10 in which air or other fluid thermally conditioned by a fluid module 14 may be selectively delivered from the fluid module 14, through a fluid distribution system 12, and to an occupant located on the vehicle seat 10. While the components of fluid module 14 (e.g., TED18, fluid delivery device 16, distribution system 12) are illustrated as being external to seat 10, one or more of these components may be positioned in whole or in part within seat 10, as desired or needed.

As shown in fig. 1, the seat assembly 10 may be similar to a standard car seat. However, it should be appreciated that some features and aspects of the seat assembly 10 described herein may also be used in a variety of other applications and environments. For example, some features and aspects of the seat assembly 10 may be used in other vehicles, such as, for example, airplanes, trains, boats, etc. In other constructions, as discussed in more detail herein, the seat assembly may include a bed (fig. 2), a hospital bed, a chair, a couch, a wheelchair, and/or any other device configured to support one or more users.

For example, fig. 2 illustrates a schematic view of a climate controlled bed 10B. The illustrated construction of the climate controlled bed 10B includes a cushion 3, a fluid distribution system 12 and a fluid module 14. Fluid module 14 may include a fluid delivery device 16 (e.g., a fan, blower, etc.), a TED18, and may include any other devices and components (e.g., sensors) as desired or needed. Fig. 2 illustrates only one configuration of a climate controlled bed 10B in which fluid module 14 is conditioned and delivered from fluid module 14 through fluid distribution system 12 to a user sitting or lying on bed 10B.

With continued reference to fig. 2, the bed assembly 10B may be similar to a standard bed. However, one or some features and aspects of the bed assembly 10B described herein may also be used in a variety of other applications and environments. For example, some features and aspects of the bed assembly 10B may be suitable for use in other stationary environments, such as chairs, sofas, theater seats, and office seats used in business and/or residential locations.

Referring to fig. 3, the fluid delivery device 116 of the fluid module 114 may be configured to provide a fluid (typically air) to the inlet 130 of the TED 118. As discussed in more detail herein, the TED may include a hot side 124 and a cold side 122. The fluid being directed through the fluid module 114 is generally divided between the hot side 124 and the cold side 122. From the cold side 122 of the TED118, fluid exits via a cold side outlet 132 that leads to the fluid distribution system 112 of the seat assembly. On the other hand, starting from the hot side 124 of the TED18, fluid exits via a hot side outlet 134 that is in fluid communication with an exhaust pipe. Such discharge pipes may convey fluid to areas where they will not affect the operation of the user of the conditioning system or the conditioning system itself.

According to some configurations, the fluids are selectively thermally conditioned as they pass through or near the TED 118. Thus, fluid exiting the TED118 through the cold side outlet 132 is relatively cold and fluid exiting the TED118 through the hot side outlet 134 is relatively hot. Also, a spacer gasket 151 may be generally positioned between the cold side outlet 132 and the hot side outlet 134. The release liner 151 may include a foam material (e.g., closed cell, open cell, etc.) and/or any other material. In some configurations, the insulation liner 151 serves to separate and thermally insulate both the hot and cold fluid streams.

Condensate Wicking (Condensate packaging)

With continued reference to FIG. 3, problems may arise when the temperature change of the cold side 122 of the TED rises above the dew point. This can, for example, cause coagulum formation. Condensation may form, for example, within the TED18, in the cold-side outlet 132, and/or at any other location within or near the TED118 or fluid module 114.

The coagulum formed within the fluid module can cause a number of potential problems. For example, a plurality of fins may be disposed along the cold side 122 and/or the hot side 124 of the TED118 to help transfer heat to or from air or other fluid passing through the fluid module 114. Based on temperature changes within the TED, condensation may form on the heat sink, generally reducing the effective surface area of the heat sink. Thus, the flow of air or other fluids through the cold side 122 of the TED118 may be partially or completely impeded. Under these conditions, the temperature of the cold side 122 may be reduced to the point where ice forms within the TED118 and/or along the cold side exit 132. Ice formation may also restrict fluid flow through the fluid module 114 and, therefore, may undesirably prevent the thermal regulation system from functioning properly.

In addition, as the coagulum forms, it may accumulate or otherwise collect on or within the TED118 and/or other portions of the thermal module 114. In some embodiments, the condensed water or other fluid may move to other downstream locations of the seat assembly, which may cause other problems. For example, such condensate may be transferred to a fluid distribution system and/or cushion of the seat assembly. As a result, mold, rust, oxidation, moisture damage, stains, and/or other problems may result. Condensate can also reduce the comfort level for the user. For example, in some cases, moist or humid air may be blown towards the user's legs, back, and/or other parts of the user's body. Moreover, condensation can create odor problems in the automobile, room, or other location where the seat assembly is located.

FIG. 4A illustrates one embodiment of the condensate formation and accumulation problems discussed herein. In the illustrated construction, the fluid module 114A includes, among other things, a fluid delivery device 116A and a TED 118A. As shown, the TED118A may be located downstream of the fan or other fluid delivery device 116A. However, in any of the embodiments disclosed herein, the TED may be alternately disposed upstream of the fluid delivery device when desired or needed. The fluid delivery device 116A may be adapted to deliver air or other fluid to the inlet 130A of the TED 118A. In some configurations, TED118A includes a hot side 124A and a cold side 122A. Thus, fluid flow may selectively proceed through inlet 130A and into TED118A, where the fluid may split between hot side 124A and cold side 122A. From the cold side 122A of the TED118A, fluid exits via a cold side outlet 132A to the fluid distribution system 112A. Similarly, starting at the hot side 124A of the TED118A, fluid exits via the hot side outlet 134A to the exhaust pipe.

According to some embodiments, as shown in FIG. 4A, a wicking barrier liner 155A is generally disposed between the cold side outlet 132A and the hot side outlet 134A. The wicking barrier liner 155A may be configured such that it wicks water and/or other fluids that condense or otherwise form within the fluid module 114A away from the cold side 122A and toward the hot side 124A. FIG. 4B illustrates one embodiment of the transfer of one embodiment of condensed water 170A and/or other fluids from the cold side to the hot side generally through the wicking barrier 155A. In some embodiments, water or other liquid entering the hot side may be conveniently evaporated or otherwise removed from the fluid module 114A.

In other embodiments, as shown in fig. 5, the wicking barrier liner 159 includes, is connected to, forms a portion of, or is otherwise in fluid communication with, the at least one finger or extended wick 157. For example, such finger wicking 157 may be configured to extend near or between one or more fins of the cold side 122 of the TED 118. The finger wicking 157 may be configured to provide faster, more efficient, more effective clot absorption. In other configurations, finger wicking 157 may be used with a release liner, but not a wicking release liner. The finger wick may be configured such that it generally wicks or otherwise transfers water or other condensate away from the cold side to the hot side where it may be conveniently evaporated or otherwise removed from the fluidic module 114. Thus, the use of finger wicking may increase the efficiency of the wicking process, and thus, the overall efficiency and effectiveness of the fluid regulatory system.

According to some embodiments, the wicking material comprises one or more of the following properties: helping to transfer water and other condensation from the cold side of the thermic module to the hot side. The wicking material may have a low thermal conductivity to provide at least a partial thermal barrier between the cold side and the hot side in the absence of condensation. Also, the wicking material may provide high capillary action. This capillary action may be in only one direction to ensure that water and other condensate are properly transferred to the hot side of the module. In addition, the wicking material may include antifungal, antibacterial, and/or other features that help prevent the generation of potentially harmful or undesirable microorganisms thereon or therein.

In some embodiments, the wicking material is configured to withstand relatively large temperature changes (e.g., short and long term changes), relative humidity, and/or the like. For example, the material may be adapted to withstand a temperature range of about 40 to 85 degrees celsius. Wicking materials can generally have a high resistance to airflow while allowing moisture to pass therethrough by capillary action. As a result, the passage of cooling fluid from the cold side to the hot side of the thermal module may be reduced or minimized. Also, the wicking material may be configured such that it has little or no dimensional deformation during use. Further, according to some constructions, the wicking material is configured to withstand forces, moments, pH changes, and/or other elements that it may be subjected to during its useful life. In some embodiments, the wicking barrier liner and/or finger wicking member comprises polypropylene, nylon, other porous or non-porous materials, and the like.

Condensate sensor

One solution to the above identified condensate formation problem is to directly treat the condensate, as discussed herein with reference to wicking materials (fig. 2-5). In other words, the condensate is allowed to appear and then removed (e.g., it is directed from the cold side to the hot side with a wicking material). This can allow the climate conditioning system to operate at or near a desired level of cooling or heating.

In other embodiments, it may be desirable or necessary to detect the presence of such condensate within or near the TED or other portion of the thermal module. Accordingly, as discussed in more detail herein, a robust but cost effective sensor may be provided to detect the presence of condensate that may be provided. Thus, once the presence of water and/or other fluids is detected by such sensors, the system may be configured to take one or more steps to eliminate condensation or otherwise remedy the problem. For example, according to one embodiment, once the sensor detects a threshold level of condensate within or near the TED, the system is designed to reduce the voltage supplied to the TED until the condensate has been completely or partially removed or reduced. This reduction in voltage may reduce the extent to which the fluid passing through the thermal module is cooled or heated, thereby reducing or stopping the formation of condensate. Such sensors may be used on or in any type of climate conditioning system and may be placed in any area where condensation may accumulate or form.

In one embodiment, the sensor detects the presence of water and/or other fluids by a change in resistance. In other embodiments, the sensor detects the presence of condensation by a change in capacitance. Additional details regarding a condensate sensor configured for use in a climate controlled seat assembly are provided herein.

6A-6E illustrate various embodiments of sensors configured to detect the presence of water and other fluids by measuring changes in resistance. As shown in fig. 6A and 6B, the sensor 40 may include a pair of

electrical traces

41, 43 or other electrically conductive members. According to some embodiments, the sensor 40 is designed to continuously monitor the resistance between

adjacent traces

41, 43. Any of the condensate sensors disclosed herein can be configured to continuously or intermittently monitor the resistance, capacitance, or other characteristic between adjacent traces, as desired or needed. Theoretically, the traces form an open circuit; in practice, however, there is a measurable resistance, for example, about 10 mega ohms, between the

traces

41, 43. The presence of fluid on the sensor 40 changes the measured resistance between the

traces

41, 43. Since many fluids, such as water, are at least partially conductive, the presence of the fluid electrically connecting the

traces

41, 43 may change the electrical resistance to a measurable degree. Thus, the loop formed by

adjacent traces

41, 43 may be "closed".

According to some embodiments, the climate control system is configured such that a change in resistance measured at sensor 40 triggers TED18 to generate a voltage drop to reduce the cooling effect by the TED. While the conditioned fluid is not too cold before the voltage is reduced, condensate formation can be reduced or stopped. Regardless, the voltage may be adapted to remain at a lower level until the resistance increases above a preset or threshold level, or until another operating criterion is met (e.g., a certain period of time has elapsed, certain upper and lower ambient temperatures have been met, etc.).

The layout, size, spacing, general positioning, and/or other details associated with the traces can be changed as needed or desired. For example, such design details may be varied based at least in part on the location of the sensor within the TED, thermal module, or other portion of the climate conditioning system, the spacing and geometry available at the target location, the method used to fabricate the sensor or form the traces at the location, the target resistance between the traces (e.g., absence of fluid, presence of fluid, etc.), and/or the like.

FIG. 6A illustrates one embodiment of a trace design. Fig. 6B shows the possible sensing zone Z for the design in fig. 6A or the zone most likely for the presence of fluid to bridge

traces

41, 43. Furthermore, water and other fluids may not bridge traces 41, 43 if located in dead zone 45 (e.g., generally a region outside of sense zone Z). As shown in fig. 6A and 6B, the

traces

41, 43 may include a main longitudinal portion and shorter arms or other members extending from the main longitudinal portion toward each other in an alternating, repeating manner. However, the

traces

41, 43 may comprise simpler or more complex designs when desired or needed. For example, as discussed herein with reference to fig. 6E, the sensor may include generally

linear traces

41, 43 that are parallel to each other.

Fig. 6C illustrates a modified embodiment of a pair of electrical traces configured for use in a coagulum sensor. As shown, the possible sensing zones may be increased because the distance between traces 41 ', 43' is maintained at substantially the same pitch throughout substantially the entire length of the sensor. In any of the trace embodiments disclosed herein or their equivalents, adjacent traces may be substantially closely spaced from one another to quickly detect condensation. The spacing between the traces may also be sufficiently large that small contaminants and other substances or the presence do not result in false detection of condensation.

FIG. 6D illustrates another embodiment of traces 41 ", 43" configured for use in a condensate sensor. The illustrated traces 41 ", 43" may be configured to reduce dead space within the sensor. For example, the spacing between adjacent traces 41 ", 43" may be maintained constant or substantially constant. Thus, due to the looped nature of the trace positioning, dead zones present therein may be advantageously reduced or eliminated. As discussed in more detail herein, in addition to dead zone reduction, other characteristics may also be considered in the sensor design, such as manufacturing cost and simplicity, durability, ability to resist corrosion, target resistance between adjacent traces, and the like. Thus, any of the trace embodiments disclosed herein, including the trace embodiments illustrated in fig. 6A-6E, may be modified as desired or needed to achieve a desired set of design criteria.

FIG. 6E illustrates yet another embodiment of electrical traces 41 '", 43'" configured for use in a coagulation sensor. As shown, the traces 41 '", 43'" can include generally linear portions that are generally parallel to one another. Any other trace structure may be used in the condensate sensor.

Another embodiment of a resistance-based sensor 90 configured to detect the presence of water or other liquid on or near a TED or other portion of a thermal module is illustrated in fig. 7. As shown, the sensor 90 may comprise a high impedance exposed chip sensor or other Surface Mounted Device (SMD). For example, such SMDs may resemble bare resistors, capacitors, and other chip devices configured to be secured to a circuit board. The sensor 90 may include a body portion 92 having a relatively high electrical resistance. According to some constructions, the body portion 92 includes a solid or porous alumina ceramic or the like. The sensor 90 may include an end 94 comprising tin or other material configured to be soldered to an adjacent conductive strip or trace. Thus, as shown, the sensor 90 may be sized, shaped, and otherwise configured to extend between adjacent

conductive traces

41, 43 located on or near a TED or other target portion of the thermal module.

With continued reference to fig. 7, the sensor 90 may be soldered or otherwise placed in electrical communication with the

electrical traces

41, 43 or other conductive member on which the resistance may be measured. Such a sensor 90 may therefore advantageously allow the

traces

41, 43 or other conductive members to which the sensor is connected to be selectively coated or otherwise protected by one or more protective coatings, layers or other members. This may help to extend the life of the

traces

41, 43. Further, such an implementation may simplify the manner in which one or more sensors 90 are disposed within the TED or other portion of the thermal module.

According to some configurations, when water or other condensation forms on or near sensor 90, such fluid may be wicked into or onto body portion 92 through one or more openings, or the like, via capillary action. Thus, the presence of water or other fluid within and/or on the body portion 92 of the sensor 90 may reduce the electrical resistance between the two end portions 94. Thus, as discussed herein with respect to other sensor embodiments, this change in resistance may confirm the presence of condensation within the thermal module. Accordingly, one or more corresponding reactions may be taken to adjust the operation of the climate control system (e.g., reduce or shut off the current to the TED).

In any of the embodiments of the sensors or other electrical devices disclosed herein (including but not limited to the sensors discussed with reference to fig. 6A-6E and 7), the electrical traces or other conductive members may be coated with one or more materials. For example, tin, silver, gold, and/or conductive or semiconductive materials may be partially or fully plated, soldered, or otherwise disposed onto the traces. Such coatings or other materials may help protect the underlying traces, which in embodiments together include copper and/or other materials that are generally susceptible to corrosion, oxidation, and other environmentally induced damage. As a result, such protective material may help extend the life of the sensor and/or other components of the thermic module.

In some embodiments, under normal circumstances, the change in resistance between adjacent traces measured by the sensor may change gradually over time. For example, as oxides, other deposits, and/or other materials accumulate on or near the traces, the resistance across the traces may change, typically decreasing, even in the absence of condensation. Conversely, when condensate is present, the resistance on the trace drops at a relatively fast rate (e.g., within seconds or minutes), depending at least in part on the rate of condensate formation and accumulation.

Thus, the thermal module and/or other portions of the climate control assembly may be configured to respond to an absolute value of the drop in resistance or a drop in resistance occurring over a short period of time. In the first case, a resistance drop below a specified threshold level triggers a drop in the voltage supplied to the TED to reduce or eliminate the formation of other condensate within the fluid module. However, this may not be desirable when the drop in resistance may be caused by normal degradation (e.g., oxidation, accumulation of other deposits and species) rather than the actual presence of condensate.

On the other hand, in a "fast change" operating scenario, the control system for the TED and other components of the thermal module may be configured to modify the voltage supplied thereto, even if a drop in the measured resistance on the trace occurs during a particular time period. Accordingly, such an implementation may facilitate more accurate detection of the presence of water or other liquids on or near the TED. Thus, this may avoid false positives, where the sensor incorrectly triggers a voltage drop to the TED. By having a sensor that measures rapid resistance changes over a short period of time, some long-term problems associated with corrosion of the sensor, deposit accumulation on sensor traces, and the like, can be avoided.

One embodiment of a curve G illustrating the decrease in resistance over time on a coagulum sensor is provided in fig. 8. As shown, the resistance on the sensor trace may gradually decrease over time due to corrosion, accumulation of dust, deposits or other substances on or near the sensor trace, and/or other factors or causes. As discussed herein, this pair is used in a TED, a thermal module andmany embodiments of condensation sensors in similar environments are typical. By way of example, during a first period t₁Meanwhile, the resistance can be reduced by the first resistance value R₁(e.g., a decrease in total resistance, a decrease in percent resistance, etc.). Such a first period t depends on the particular environmental and operating conditions encountered by the sensor₁Which may include days, months or years.

With continued reference to FIG. 8, the resistance may drop by a second resistance value R, primarily due to the accumulation of water or other condensate on the sensor₂. Such a resistance value R₂The time period occurring may be substantially short (e.g., seconds, minutes, etc.), particularly with respect to R₁When compared. Thus, suppose a formula represented by R₁And R₂The drop in the total resistance (percent resistance) represented is substantially equal, then a sensor that does not factor in time may not be able to operate at period t₁Gradual resistance drop and period t during₂A distinction is made between rapid resistance drops during the period. Thus, the sensor may not be able to adequately detect the presence of condensate.

To correct for this difference, in some embodiments, the climate control system is configured to compare a particular resistance drop measured at the sensor before and after a time period in which the drop occurs. Thus, the system may be configured to modify the voltage supplied to the TED only when the condensate sensor detects a particular resistance value or percentage drop within a minimum time period. For example, according to some configurations, the system will adjust the temperature of the TED if the resistance drops by at least 5%, 10%, 15%, 20%, greater than 20%, or some other value over a 1 minute, 2 minutes, 5 minutes, 10 minutes, 15 minutes, 30 minutes, or other time period. In other configurations, the minimum percentage of resistance drop and/or the time period over which such a resistance drop must occur may be varied as desired or needed.

In some embodiments, electrical traces may be etched on the surface. As discussed in more detail herein, such surfaces may be on or form part of TED18, fluid distribution system 12, or other devices or assemblies of a climate controlled system for a seat assembly (fig. 1 and 2) or any other device.

The sensors will now be discussed in connection with the TED218 illustrated in fig. 9A and 9B. As shown, TED218 may include a plurality of dissimilar conductive elements or

pellets

222, 224. In some configurations, the dissimilar conductive element pairs 222, 224 are joined together by a series of electrical connection elements or tabs 228, which electrical connection elements or tabs 228 are in turn disposed between a pair of opposing substrates 232. The substrate 232 may comprise polyimide, ceramic, epoxy, or other material having desired electrical insulating and thermal conductive properties. In the illustrated embodiment, each base plate 232 is thermally bonded to a heat transfer member 238 (e.g., a heat sink) by one or more copper pads 234 or other support members. In some embodiments, a seal 260 is optionally disposed between the opposing substrates 232 to help protect the

elements

222, 224 positioned therebetween.

According to various embodiments disclosed herein, one or more condensate sensors may be used with TED218 to detect the presence of water or other fluids. In some embodiments, the sensor is disposed substantially along or near the substrate on a side opposite the pellet at a downstream side of the TED. Since in some configurations the cold downstream side of the TED is one of the coldest or coldest locations in the thermal module, condensation may form at or near that location. However, in other embodiments, one or more condensation sensors are positioned on the thermal module and/or other portions of the climate control seat assembly along or near the TED218 (e.g., heat sink, copper pad, etc.) as desired or needed. Accordingly, embodiments disclosed herein, including advantages, features, and other details presented herein, may be applicable to any condensation sensor included within a climate controlled seat assembly, regardless of its location, type, and/or other characteristics.

Fig. 10A illustrates a different embodiment of a fluidic module 214'. As shown, the TED218 'may include a substrate 320 that is generally longer than the adjacent thermally conductive element 234' and may form a ledge or shelf. In some embodiments, the sensor 240 is formed on the protruding portion 270 of the substrate 320. A portion of the air or other fluid entering through the inlet 250 'of the fluid module 214' is diverted to the primary side 252 'and passes through the heat transfer member 238' (e.g., a heat sink). In some configurations, the fluid passing through the primary side heat transfer member 238' is selectively cooled. Thus, condensation may form on the heat transfer member 238 ' and/or anywhere on the TED218 ' or fluid module 214 '. Some of the condensate may contact the sensor 240, which may be configured according to one embodiment disclosed herein or a variation thereof. Accordingly, the sensor 240 may be configured to detect condensation and directly or indirectly trigger a voltage drop supplied to the TED 18'. For example, in some embodiments, the sensor 240 is operatively connected to a controller adapted to receive data from the sensor and adjust the voltage supplied to the TED accordingly. FIG. 10B illustrates another embodiment of a TED218 ' of a sensor 400 that includes a ledge 270 ' or other extension along the substrate 320 '. The number, type, size, shape, location, and/or other details associated with condensation sensors used in thermal modules or TEDs and/or other portions of climate control systems may be changed as desired or needed.

In some embodiments, as shown in fig. 10C, the TED218 "", includes fins 238 "" (or other heat transfer means) along its discharge side 255 "", but not along its main side 252 "". Such a configuration may place a particular item in thermal communication with the primary side 252 "" of the TED218 "" with heating or cooling. In some embodiments, such structures are used to selectively heat and/or cool beverage containers and the like. By way of example, the item 101 to be chilled (e.g., a beverage container, food item, etc.) may be placed directly on the primary side 252 "" of the TED. When TED18 "" is activated (e.g., electrically energized), primary side 252 "" may be configured to cool. Thus, the object 101 may be cooled in a conductive and/or convective manner. In some configurations, one or more condensate sensors 240 "" are positioned on the ledge 270 "", other locations of the substrate 320 "", and/or other locations of the TED218 "". For example, the condensate sensor is disposed on or along the same surface as the article 101 to be cooled.

According to some embodiments, the sensor is configured to detect the presence of water and/or other condensate by measuring capacitance. Such sensors may function in a similar manner to resistance-based sensors, where a change in capacitance may be correlated to the presence of condensation on or near the sensor. Thus, the climate control system may be configured to reduce the voltage supplied to the TED to partially or completely eliminate such condensate from the system.

As discussed, in any of the embodiments disclosed herein, the climate control system may be configured to restore the current supplied to one or more TEDs to its starting or other value once the sensors no longer detect the presence of condensate.

In some configurations, capacitance-based sensors may provide some advantages over resistance-based sensors. For example, as discussed in more detail herein, resistance-based sensors may be susceptible to damage (e.g., by corrosion, contamination, etc.). However, there are also some situations where resistance-based sensors may be preferable to capacitance-based sensors. In discussing any deficiencies in the various alternatives (e.g., coagulum sensors) herein, applicants in no way deny any other devices, systems, methods, design features, and/or other characteristics or aspects using such embodiments or other equivalents, as each may require balancing features and criteria that may be different for the other.

FIG. 11A illustrates one embodiment of a capacitance-based sensor 280. As shown, the sensor 280 may include a first plate 281, a second plate 283, and a material 285 or intermediate portion generally located between the first plate 281 and the second plate 283. The first plate 281 and the second plate 283 may include one or more conductive materials. The material 285 or intermediate portion of the sensor 280 may include one or more materials configured to absorb a fluid (e.g., water, other liquids, condensation, etc.). According to some embodiments, as the humidity level within the material 285 changes, the capacitance measured between the first plate 281 and the second plate 283 also changes. The change in capacitance measured by the sensor 280 above a certain set point or threshold may be configured to cause the voltage supplied to the TED to decrease. In some configurations, such a TED may be adapted to operate at a reduced voltage until the capacitance measured between the first plate 281 and the second plate 283 returns to a predetermined or suitable level. For example, once the capacitance increases above the same threshold that causes the voltage to decrease, the voltage to the TED may increase. Thus, when the capacitance increases above a given set point, a controller operatively connected to the sensor and the TED directs the voltage supplied to the TED back to the starting level. In other embodiments, the climate control system is configured to have two or more different capacitance levels or thresholds above or below which the voltage supplied to the TED is modified (e.g., increased, decreased, etc.).

According to some configurations, the change in capacitance measured at the sensor 280 causes a voltage drop to the TED to reduce the cooling effect on the thermally conditioned fluid. Thus, since the conditioned fluid is not as cold as it was before the voltage drop, it may be advantageous to stop or reduce the formation of condensate. As discussed, in this case, the voltage may be maintained at a lower level until the capacitance increases above the target threshold. Once the target threshold capacitance is reached, the supply of current to the TED may be restored to a previous level or other levels according to the target control plan.

In some configurations, it is advantageous that the capacitance-based sensor is used in a TED that includes a flexible substrate. However, resistance-based or other types of condensation sensors may also be used for such TED. In some embodiments where the TED includes a ceramic substrate, a resistance-based condensate sensor may be used.

According to some embodiments, the material 285 or an intermediate portion positioned generally between the

conductive plates

281, 283 of the capacitance-based sensor 280 may also serve as a substrate layer for the TED. For example, a flexible substrate such as polyimide may be suitable for absorbing fluids. Thus, when such a substrate absorbs water or other fluid formed on or within the TED, the sensor 280 may detect a corresponding change in capacitance measured between its

plates

281, 283. Since polyimide is generally highly hygroscopic, it is very suitable for such applications. In other embodiments, one or more other materials may be used to serve the dual function of a TED substrate and a material layer for a capacitance-based condensate sensor. Moreover, even materials having average or poor moisture absorption characteristics (e.g., in combination with other materials, providing various structures, etc.), such as ceramics, may be modified to use them in such applications.

Referring to fig. 11B, among other things, the capacitance-based sensor may include a thermally conductive element 134, an electrical connection element or tab 128, and a substrate 132. In some embodiments, the thermally conductive element 134 and the electrical connection element 128 may be configured as a first electrically conductive plate 81 'and a second electrically conductive plate 283', respectively, that function as a sensor. The substrate 132 may effectively be a material or intermediate portion of the capacitance-based sensor that is generally positioned between the upper and lower conductive plates. As discussed, the substrate 132 may include one or more materials that absorb water and other fluids. Therefore, when the substrate absorbs the condensate, the capacitance measured between the first conductive plate 281 'and the second conductive plate 283' may be changed. This change in capacitance may signal the presence of an undesirable amount of condensate at or near the TED. Thus, the climate control system may be advantageously configured to reduce the magnitude of the voltage supplied to the TED. In some embodiments, the first conductive plate 281 'and the second conductive plate 283' comprise copper and/or other highly conductive materials.

In some embodiments, the substrate layers used in the TED may be relatively thin. For example, the polyimide substrate may have a thickness of less than 0.001 inch (0.025 mm). Thus, the surface area exposed for moisture absorption may also be relatively small. For example, the exposed surface area may comprise only the length of the exposed edge. In some embodiments, the exposed surface area is increased by a variety of methods. For example, the first conductive plate 281' may include holes allowing more enhanced moisture absorption. In other embodiments, the first conductive plate 281' includes a plurality of holes. The holes may be located in or along a localized area. Alternatively, such a hole may extend substantially along the first conductive plate 281'. In other configurations, the holes are concentrated where the likelihood of condensate formation is relatively high, e.g., on the primary side, typically downstream of the TED gas flow. In other constructions, the holes are located on the protruding portions, or on other protruding members or portions that extend beyond the primary side heat transfer member 138 of the TED.

Fig. 12 schematically illustrates a condensate sensor 40 (e.g., a resistance-based sensor, a capacitance-based sensor, etc.) that has been incorporated into a circuit, according to any of the embodiments disclosed herein. In some embodiments, existing or commercially available sensors may be used in or near a thermal module and/or other location of a climate control system instead of or in addition to any of the particular sensor embodiments disclosed herein. As shown, the voltage across the sensor 40 can be measured by applying a voltage (e.g., 5V) and a resistance (e.g., 1 megaohm) upstream of the sensor 40.

While the condensate sensor disclosed herein is described primarily in the context of TEDs and climate control systems for seat assemblies, it will be appreciated that these embodiments and variations thereof are also applicable to other applications. For example, such a sensor may be used in conjunction with any heating and/or cooling system in which condensation may form or in which water or other liquids may accumulate. Moreover, such sensors may be used to detect condensation on printed circuit boards for electronics, other electronic components, and/or any other electrical or mechanical device from which it is important to remove fluid. In other embodiments, such sensors are independent electrical sensors that generate a signal (e.g., 5V) when coagulum forms.

Control scheme using relative humidity and/or temperature sensing

Advantageously, climate controlled seat assemblies, such as vehicle seats, beds, wheelchairs, and the like, may be configured to automatically operate in a desired comfort zone. One embodiment of such a comfort zone is schematically illustrated in the graph 500 of fig. 13 (generally represented by the shaded area 510 drawn with intersecting parallel lines). As shown, the target comfort zone 510 may be based at least in part on the temperature and relative humidity of a particular environment (e.g., ambient air, thermally conditioned air or other fluid passing through the climate controlled seat assembly, etc.). Thus, if the relative humidity at a particular temperature is too low or too high, or vice versa, the comfort level of a passenger located in such an environment may be reduced, or such comfort level is often outside the target area.

For example, referring to the conditions generally represented by point 520C on the curve 500 of FIG. 13, the relative humidity at a particular temperature is too high. Alternatively, it can be said that the temperature at point 520C is too high for a particular relative humidity. However, in some embodiments, to improve the comfort level of passengers present in that environment, the climate control system may be configured to strive to change ambient conditions to achieve the target comfort zone 510 (e.g., in the direction generally indicated by arrow 520C). Likewise, the climate control system for the seat assembly located in the environmental condition represented by point 520D may be configured to operate in an effort to change the ambient conditions to achieve the target comfort zone 510 (e.g., in the direction generally represented by arrow 520D). In fig. 13, the environmental conditions, generally represented by

points

520A and 520B, have been within the target comfort zone 510. Thus, in some embodiments, a climate control system may be configured to maintain such ambient environmental conditions at least while a passenger is located in a corresponding seat assembly (e.g., a vehicle seat, a bed, a wheelchair, etc.).

In some embodiments, a climate control system for a seat assembly is configured to include other comfort zones or target operating conditions. For example, as schematically illustrated in fig. 13, the second comfort zone 514 may be included as a smaller area within the primary comfort zone 510. The second comfort zone 514 may represent a combination of better environmental conditions (e.g., temperature, relative humidity, etc.) than other portions of the primary comfort zone 510. Thus, in fig. 13, the environmental conditions represented by point 520B, while in the primary comfort zone 510, fall outside of the second, better comfort zone 514. Accordingly, the climate control system for the seat assembly located in the ambient condition represented by point 520B may be configured to operate to change the ambient condition to the second comfort zone 514 (e.g., in the direction generally represented by arrow 520B).

In other embodiments, the climate control system may include one, two, or more target comfort zones, as desired or needed. For example, a climate control system may include separate target zones for summer and winter operation. Thus, in such a configuration, the climate control system may be configured to detect the age and/or anticipated comfort zone in which the climate controlled seat assembly will operate.

Incorporating such automatic control modes into a climate control system typically presents a more complex method of operating a climate controlled seat assembly (e.g., a bed). Moreover, as discussed herein, such a pattern may also help simplify the climate controlled seat assembly and/or reduce costs (e.g., manufacturing costs, operating costs, etc.). This is particularly important where a position threshold comfort level is required or highly desirable, for example for patients located in wheelchairs, medical beds, and the like. Moreover, such control modes are applicable to seat assemblies configured to receive passengers with limited mobility and/or seat assemblies in which passengers are typically sitting for extended periods of time (e.g., beds, airplane seats, other vehicle seats, movie theaters, hospital beds, rehabilitation beds, wheelchairs, etc.).

According to some embodiments, data or other information obtained by one or more sensors is used to selectively control the climate control system to achieve environmental conditions within the desired comfort zones 510, 514 (fig. 13). For example, the climate control system may include one or more temperature sensors and/or relative humidity sensors. As discussed in more detail herein, such sensors may be located along portions of the seat assembly (e.g., TEDs, thermal modules, fluid distribution systems, inlets or outlets of fluid delivery devices, fluid inlets, surfaces of the assembly opposite where seated passengers are located, etc.) and/or other locations located within the same surrounding environment as the seat assembly (e.g., car interior locations, bedrooms, sickrooms, etc.). In other embodiments, one or more other types of sensors may also be provided, such as an occupant detection sensor (e.g., configured to automatically detect when an occupant is seated on a vehicle seat, bed, and/or any other seat assembly).

Regardless of the number, type, location, and/or other details associated with the various sensors included within a particular assembly, the various assemblies of the climate control system may be configured to operate (preferably automatically, in one embodiment) according to a target control algorithm. According to some embodiments, the control algorithm includes a level of sophistication such that it automatically varies the amount of heating and/or cooling provided at the seat assembly based at least in part on existing environmental conditions (e.g., temperature, relative humidity, etc.) and the target comfort zone.

Thus, in some embodiments, a control system for a climate controlled seat assembly is configured to receive input into its control algorithm data from one or more locations as well as other information regarding temperature and relative humidity. For example, as shown in fig. 14A, a climate controlled vehicle seat 600 may include a

fluid distribution system

612, 622 along its seatback portion 602 and/or seat bottom portion 604. Each

fluid distribution system

612, 622 may be in fluid communication with a fluid delivery device 616, 626 (e.g., a fan, blower, etc.) and a thermoelectric device 618, 618 (e.g., a peltier circuit, other device configured to selectively temperature regulate air or other fluid passing therethrough, etc.). In the illustrated construction, a

temperature sensor

630, 632 is located within or near each thermoelectric device 618, 628.

Such sensors

630, 632 may be configured to detect the temperature of the TED, the temperature of a heat sink or other heat transfer member, the temperature of any other portion or component of the TED, the operating temperature of the TED, the temperature of fluid within, into, or out of the heat sink or other portion of the TED, the temperature upstream or downstream of the fluid delivery device, the temperature within the

fluid distribution system

612, 622, and/or the temperature along any other portion of the thermal module or seat assembly.

With continued reference to fig. 14A, instead of or in addition to the

temperature sensors

630, 632 included on or near the TED, one or

more sensors

654, 656 may be disposed at the controller 650 and/or any other location around the seat assembly 600. For example, the illustrated controller 650 may include a sensor 654 configured to detect ambient temperature. Moreover, the controller 650 may also include a sensor 656 configured to detect the relative humidity of the surrounding environment (e.g., the interior or exterior of the automobile). Although not included in the illustrated configuration, one or more additional relative humidity sensors may be disposed on or near the TED, within the fluid distribution system of the seat assembly 600, at any location where a temperature sensor is disposed (e.g., upstream or downstream of the fluid delivery device), and so forth. Such a relative humidity sensor may be configured to provide other operational data that may further enhance the ability of the climate control system to automatically operate within the desired comfort zones 510, 514 (fig. 13).

As shown in fig. 14A, the controller 650 may be operably connected to a plurality of

sensors

630, 632, 654, 656 located within or near the climate controlled seat assembly 600. The information received from the plurality of sensors may be used to automatically control one or more devices or aspects of the climate control system, such as the TEDs 618, 628 (e.g., the magnitude of the voltage supplied to them), the fluid delivery devices (e.g., the rate at which air is transmitted through the fluid distribution systems 612, 622), and so forth. In other embodiments, the controller 650 is also operatively connected to one or more external climate control systems (e.g., an HVAC system of an automobile or building). This can further enhance the ability of the climate control system to achieve desired operating conditions.

In other embodiments, as shown in the bed assembly 700 of fig. 14B, both the

temperature sensors

730, 732 and the

relative humidity sensors

740, 742 are disposed within or near the

TEDs

718, 728 or fluid modules in which such TEDs are disposed (e.g., inlets of the fluid delivery devices 716, 726). In other constructions, other temperature and/or

relative humidity sensors

754, 756 are included in other portions of the bed assembly 700 (e.g., in the lower portion 714 and/or upper portion 712, in the

fluid distribution members

712, 713, etc.), on the controller 750, on a wall of a room in which the bed assembly 700 is disposed, and so forth.

Regardless of the number, type, location, and/or other details associated with the various sensors used in conjunction with the climate control system, such sensors may advantageously be configured to provide data and other information regarding the temperature and relative humidity of the ambient air, the operating temperature of a particular climate controlled seat assembly (e.g., vehicle seat, bed, wheelchair, etc.), and the like, to allow for operation of the seat assembly within a target comfort zone (e.g., automatically if desired).

For example, as discussed herein with reference to fig. 14A, information communicated from the various sensors to the controller may be used to automatically open or close and/or adjust various components of the climate controlled bed 700 or other seating assembly. In some configurations, the fluid delivery device and/or TED is turned on or off depending on the desired control mode. As discussed, such beds and other seat assemblies may also include occupant detection sensors that allow the control system to be informed when a user is seated or otherwise situated thereon. Thus, the bed assembly 700 can be configured to automatically open or close and/or provide different levels of hot and/or cold air on which the occupant is positioned. This may advantageously eliminate the need for one or more manual controls (e.g., switches, controllers, etc.) that may be supplied by the climate controlled bed 700 or the seat assembly. Thus, such an automatic mode of operation may advantageously reduce the cost and complexity of providing and operating a climate controlled bed or other assembly.

In any of the embodiments disclosed herein or other equivalents, the relative humidity sensor may be capacitance-based, resistance-based, thermal conductivity-based, or the like.

In a simpler embodiment, the control algorithm is configured to receive temperature data only from one or more sensors. Alternatively, only a relative humidity sensor may be used to provide information to the climate control system regarding existing environmental conditions within or near the target seat assembly. In other embodiments, the control system is provided with other information about the surrounding environment, such as, for example, the time of day, whether the ambient temperature is falling or rising, and the like. Thus, the target comfort zone 510 (e.g., fig. 13) may be based on one, two, three, or more variables when desired or needed.

Moreover, as discussed and illustrated in greater detail herein, any of these control modes may be used with a condensate sensor and/or a capillary flow separator. For example, if the condensate sensor detects an undesirable level of fluid present within the TED and/or other location of the thermal module, the control mode of operation within the target comfort zone may be overridden. Alternatively, if a wicking material is provided within the thermic module for proper avoidance of coagulum formation, the control mode may be configured to continue operation toward the target comfort zone.

The systems, devices, apparatuses, and/or other articles disclosed herein may be formed by any suitable means. The various methods and techniques described above provide a number of ways to implement the present invention. Of course, it is to be understood that not necessarily all such objects or advantages described may be achieved in accordance with any particular embodiment described herein. Thus, for example, those skilled in the art will recognize that the methods may be performed in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objectives or advantages as may be taught or suggested herein.

Moreover, one skilled in the art will recognize the interchangeability of various features from different embodiments disclosed herein. Similarly, the various features and steps discussed above, as well as other known equivalents for such features or steps, can be mixed and matched by one of ordinary skill in this art to perform methods in accordance with principles described herein. Further, the methods described and illustrated herein are not limited by the actual order of the acts described, nor are they necessarily limited to practice of the acts presented. Other sequences of events or actions, or less than all events, or the simultaneous occurrence of events, may be used to practice embodiments of the invention.

Although the invention has been disclosed in the context of certain embodiments and examples, it will be understood by those skilled in the art that the invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses and modifications and equivalents thereof. Accordingly, it is not intended that the invention be limited, except as by the appended claims.

Claims

1. A fluid regulating device for use with a climate controlled seat assembly, the device comprising:

a fluidic module comprising a housing;

a fluid delivery device configured to deliver fluid through the interior of the housing;

a thermoelectric device configured to selectively heat or cool a fluid passing inside the housing;

wherein the thermoelectric device includes a hot side and a cold side, the hot side in fluid communication with the hot channel and the cold side in fluid communication with the cold channel;

wherein the thermal channel is configured to receive air heated by the thermoelectric device;

wherein the cold aisle is configured to receive air cooled by the thermoelectric device;

wherein the hot and cold channels are located downstream of the thermoelectric device and within the housing of the fluidic module;

a separator gasket located within the housing and at least partially between the cold channel and the hot channel, the separator gasket comprising a wicking material; and

at least one wicking material finger extending at least partially through the housing to the thermoelectric device, the at least one wicking material finger configured to transport liquid from the thermoelectric device to the release liner,

wherein the separator gasket is configured to transport liquid from the cold channel to the hot channel, the separator gasket configured to wick liquid from a first side of the separator gasket on a cold side of the thermoelectric device through the separator gasket to a second side of the separator gasket on a hot side of the thermoelectric device, the first side of the separator gasket opposite the second side.

2. A fluid regulating device in accordance with claim 1, wherein the release liner comprises a porous structure.

3. The fluid regulating device of claim 1, wherein the wicking material comprises polypropylene or nylon.

4. The fluid regulating device of claim 1, wherein the liquid delivered to the thermal channel is configured to be evaporated.

5. The fluid regulating device of any one of claims 1-4, wherein the at least one finger extends proximate one or more fins forming at least a portion of a cold side heat exchanger of the cold side of the thermoelectric device.

6. The fluid regulating device of any one of claims 1-4, wherein the insulating liner comprises one or more wicking materials that at least partially separate the cold channel from the hot channel.

7. A fluid regulating device in accordance with any one of claims 1 to 4, wherein the thermoelectric device is positioned downstream of the fluid delivery device.

8. A fluid regulating device in accordance with any one of claims 1 to 4, wherein the thermoelectric device is positioned upstream of a fluid delivery device.

9. A fluid module for selectively heating and/or cooling air, the fluid module comprising:

a thermoelectric device having a cold side and a hot side;

the cold side of the fluidic module includes a cold side heat transfer member coupled to the cold side of the thermoelectric device and a cold channel in fluid communication with the cold side heat transfer member;

the hot side of the fluid module includes a hot side heat transfer member coupled to the hot side of the thermoelectric device and a thermal channel in fluid communication with the hot side heat transfer member; and

a separator gasket configured to transport liquid from at least a portion of the cold side channel to the hot side channel, the separator gasket configured to wick liquid from a first side of the separator gasket on the cold side of the thermoelectric device through the separator gasket to a second side of the separator gasket on the hot side of the thermoelectric device, the first side of the separator gasket opposite the second side;

wherein the release liner comprises at least one finger extending on the cold side of the thermoelectric device.

10. The fluidic module of claim 9, wherein said at least one finger extends proximate to one or more fins forming at least a portion of said cold side heat transfer member.

11. The fluidic module of claim 9, wherein the spacer includes one or more wicking materials that at least partially separate the cold side channel from the hot side channel.

12. The fluidic module of claim 11, wherein the one or more wicking materials comprise polypropylene or nylon.

13. The fluidic module of any of claims 9 to 12, comprising a fluid transport device configured to provide fluid to a cold side and a hot side of the thermoelectric device, wherein the thermoelectric device is positioned downstream of the fluid transport device.

14. The fluidic module of any of claims 9 to 12, comprising a fluid transport device in fluid communication with the cold side channel and the hot side channel, wherein the thermoelectric device is positioned upstream of the fluid transport device.

15. The fluidic module of any of claims 9 to 12, wherein the release liner comprises a porous structure.

16. A method of selectively heating and/or cooling air, the method comprising:

transferring air to a cold side of a fluidic module, the cold side of the fluidic module including a cold side heat transfer member coupled to the cold side of the thermoelectric device and a cold channel in fluid communication with the cold side heat transfer member;

transmitting air to a hot side of the fluid module, the hot side of the fluid module including a hot side heat transfer member coupled to the hot side of the thermoelectric device and a thermal channel in fluid communication with the hot side heat transfer member; and

wicking condensate from at least a portion of the cold side of the fluidic module;

wherein wicking condensate from at least a portion of the cold side of the fluidic module includes wicking condensate through a separator gasket separating the cold side channel from the hot side channel, the separator gasket configured to wick condensate from a first side of the separator gasket on the cold side of the thermoelectric device through the separator gasket to a second side of the separator gasket on the hot side of the thermoelectric device, the first side of the separator gasket opposite the second side, and

wherein wicking condensate from at least a portion of the cold side of the fluidic module includes wicking condensate through at least one finger wick extending over the cold side of the thermoelectric device.

17. The method of selectively heating and/or cooling air according to claim 16, further comprising wicking condensate to a hot side of the fluid module.

18. The method of selectively heating and/or cooling air according to claim 16, wherein the release liner includes the at least one finger wick.

19. The method of selectively heating and/or cooling air of claim 16, wherein wicking condensate from at least a portion of the cold side of the fluid module comprises wicking condensate through the at least one finger wick that extends proximate to one or more fins forming at least a portion of the cold side heat transfer member.

20. The method of selectively heating and/or cooling air of any of claims 16-19, wherein wicking condensate from at least a portion of the cold side of the fluid module includes wicking condensate along the at least one finger wick that extends proximate to one or more fins forming at least a portion of the cold side heat transfer member.

21. The method of selectively heating and/or cooling air of any of claims 16 to 19, comprising transferring air to the cold side heat transfer member and the hot side heat transfer member via a fluid transport device, wherein the thermoelectric device is positioned downstream of the fluid transport device.

22. The method of selectively heating and/or cooling air of any of claims 16 to 19, comprising transferring air to the cold side heat transfer member and the hot side heat transfer member via a fluid transport device, wherein the thermoelectric device is positioned upstream of the fluid transport device.